View
217
Download
0
Category
Preview:
Citation preview
© 2013 NobelClad. All rights reserved. A DMC Company
Curtis Prothe, Christoph Hurley, John Banker DMC NobelClad Stephen Liu, PhD Colorado School of Mines 20 June, 2016
Comparative Tensile and Shear Strength of Explosion Clad Materials
NobleClad.com
TOPICS
• Background – Motivation for Test Program
• Experimental Design and Test Results
• Conclusions
COMPARATIVE TENSILE AND SHEAR STRENGTH OF EXPLOSION CLAD MATERIALS
NobleClad.com
Background – Motivation for test program
Comparative Tensile and Shear Strength of Explosion Clad Materials
NobleClad.com
BACKGROUND – MOTIVATION FOR TEST PROGRAM
• Cladding metal thickness typically too thin for tensile test coupon
• Clad specifications do not require clad tensile testing or identify minimum strength requirements
• Shear testing is common, but clad tensile strength data limited
NobleClad.com
WELD INTERNALS DIRECT
• Direct Welding Attachment of Internals
• In clad vessels, internal attachments to the vessel wall are frequently required
• Many companies require clad strip-back (especially for “heavy” internals) • Lack of data to support design • Concerns with clad separation
CRUDE DISTILLATION COLUMN
NobleClad.com
ADVANTAGES AND PROPERTIES OF EXW
EXW for Pipe Applications
1. Bond Quality
Disbonding of Roll Bonded Clad Plates after forming and welding
X65Q 31.1 mm + Alloy 625 3.1 mm OD 53“ (caisson)
X65Q 35.6 mm + Alloy 625 3.5 mm OD 39“, 90°/5D induction bend
NobleClad.com 7
Attachment with Clad Strip-back
Process Steps: 1) Strip back cladding 2) Inspect 3) Weld attachment to
steel base metal (dissimilar metal weld)
4) Inspect 5) Complete CRA weld
overlay 6) Inspect
WELDING INTERNALS DIRECT
NobleClad.com 8
Direct Attachment with NobelClad EXW Clad
Process Steps: 1) Weld attachment
directly to cladding metal
2) Inspect
Direct Attachment • Reduces cost $$$ • Less time in shop • No dilution or dissimilar
metal welding • Improves design
flexibility
WELDING INTERNALS DIRECT
NobleClad.com
WELD INTERNALS DIRECT
• Direct Welding Attachment of Internals
• Requires reliable, high strength cladding
• Testing program initiated by NobelClad to investigate clad tensile strength
CRUDE DISTILLATION COLUMN (Photo courtesy of Dacro Industries)
NobleClad.com
Experimental Design and Test Results
Comparative Tensile and Shear Strength of Explosion Clad Materials
NobleClad.com
EXPERIMENTAL DESIGN AND TEST RESULTS
• Phase I
• Testing of a broad range of explosion clad production materials
• Clad tensile strength is compared to the shear strength, and the cladding and base metal properties.
• Phase II describes a second series of tests focused on
• Materials that are typical for oil & gas applications
• Covers testing of coupons that simulate in-service conditions (welded coupons, SPWHT, elevated temperature testing, cantilever loading of welded attachment).
NobleClad.com
EXPERIMENTAL DESIGN AND TEST RESULTS – PHASE I
12
• Test material selected from NobelClad production plates
• Cladding metal thickness>= 9.5mm
• Heat treatment = production plate HT
• Tests machined from the same test block for direct comparison
• Shear
• Sub-size Clad Tensile (6.4mm gauge diameter)
• Base Metal Tensile
NobleClad.com
EXPERIMENTAL DESIGN AND TEST RESULTS – PHASE I
NobleClad.com
EXPERIMENTAL DESIGN AND TEST RESULTS – PHASE I
NobleClad.com
EXPERIMENTAL DESIGN AND TEST RESULTS – PHASE I
NobleClad.com
SHEAR STRENGTH VS. TENSILE STRENGTH
NobleClad.com
EXPERIMENTAL DESIGN AND TEST RESULTS – PHASE I
17
NobleClad.com
• Covers testing focused on typical oil & gas materials and conditions
• Clad Tensile Testing • SA387-22-2, SA516-70 base metal • SA240-317L, -347 clad metals • 4.8mm cladding metal and welded test coupons • Elevated temperature testing (RT to 650°C) • Multiple cycles of SPWHT, step cooling heat treatments • Evaluation of Tensile Strength and HAZ with reduced cladder thickness
• Cantilever loading of welded attachment
• Tensile testing with simulated non-bond
18
EXPERIMENTAL DESIGN AND TEST RESULTS – PHASE II
NobleClad.com 19
EXPERIMENTAL DESIGN AND TEST RESULTS – PHASE II
16mm
NobleClad.com
50X, Nital Etch
SA240-347 Clad SA387-22-2 Base
Full penetration weld of attachment No change in steel structure at bond interface
NobleClad.com
• Clad tensile testing
• Fractures in base metal
EXPERIMENTAL DESIGN AND TEST RESULTS – PHASE II
NobleClad.com
NobleClad.com
NobleClad.com
NobleClad.com
NobleClad.com
EVALUATION OF TENSILE STRENGTH AND HAZ WITH REDUCED CLADDER THICKNESS
• Evaluate minimum clad thickness required for direct attachment welding without affecting the base metal
• Demonstrate tensile properties without PWHT
4.8mm
3.2mm
2.3mm
1.5mm 0.8mm
NobleClad.com
TEST SET UP AND TENSILE RESULTS
• 4.8mm Clad: 593 MPa
• 3.2mm Clad: 589 MPa
• 2.3mm Clad: 598 MPa
• 1.5mm Clad: 590 MPa
• 0.8mm Clad: 610 MPa
• All failure locations were in the SA 387-22-2 base metal
16mm
NobleClad.com
WELDING PARAMETERS
• Process: GMAW
• Shielding Gas: 90% He, 7.5% Ar, 2.5% Co2
• Filler Metal: ER347
• Current: 181 Amps
• Voltage: 21 Volts
• Travel Speed: 10 IPM
• Wire Feed Speed: 350 IPM
• Heat Input: 22,806 Joules per inch
NobleClad.com
EVALUATION OF HAZ
0.8mm Clad Thickness 3.2mm Clad Thickness
NobleClad.com
EVALUATION OF HAZ
EXW Interface
NobleClad.com
CANTILEVER LOADING OF WELDED ATTACHMENT
• Application mock-up testing
• Bending moment on a welded attachment.
• Loaded to failure on the production press.
• After loading , samples cut for metallographic examination and evaluation.
NobleClad.com
No clad separation or disbond
Cracking in attachment weld
CANTILEVER LOADING OF WELDED ATTACHMENT
NobleClad.com
TENSILE TESTING WITH SIMULATED NON-BOND IN CLADDING
• Application mock-up testing • 25mm flat bottom hole drilled to the
interface to simulate a 25mm non-bond.
NobleClad.com
Load at Break = 525 kN No disbond at simulated non-bond
TENSILE TESTING WITH SIMULATED NON-BOND IN CLADDING
NobleClad.com
COMPARATIVE TENSILE AND SHEAR STRENGTH OF EXPLOSION CLAD MATERIALS
Conclusions
• The clad tensile strength exceeded the shear strength for 100% of the materials tested
• The through thickness tensile strength of explosion welded titanium alloy and copper alloy clad are well above the cladding metal minimum tensile strengths
• For explosion welded stainless steel and nickel alloy clad, the tensile strength of explosion weld • Exceeded the tensile strength of the steel base metal and • Meets the base metal minimum tensile strength requirement. • Tensile strength maintained for thinner cladding metal, welded test coupons, with
various heat treatment conditions, and at elevated temperature • Mock-up testing did not produce any clad separation or disbonding
NobleClad.com
COMPARATIVE TENSILE AND SHEAR STRENGTH OF EXPLOSION CLAD MATERIALS
Conclusions
• Tensile strength data of NobelClad EXW material supports direct attachment to the clad surface
© 2013 NobelClad. All rights reserved. A DMC Company
Curtis Prothe 1138 Industrial Park Drive Mount Braddock, PA 15465 cprothe@nobelclad.com
Thank you
Recommended